Remote Automation Solutions FB2100/FB2200 Flow Computer CPU Enclosure and Electronics Field User guide

Brand
Remote Automation Solutions
Model
FB2100/FB2200 Flow Computer CPU Enclosure and Electronics Field
Type
User guide
FB2100/FB2200 Flow Computer CPU Enclosure and Electronics Field Replacement Guide
D301803X012
November 2020
Remote Automation Solutions
FB2100/FB2200 Flow Computer
CPU Enclosure and Electronics
Field Replacement Guide
For Part Numbers (Kits):
See page 2 for field replacement kit part numbers
FB2100/FB2200 Flow Computer CPU Enclosure and Electronics Field Replacement Guide
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November 2020
Device Safety Considerations
Reading these Instructions
Before operating the device, read these instructions carefully and understand their safety implications. In some situations,
improperly using this device may result in damage or injury. Keep this manual in a convenient location for future reference.
Note that these instructions may not cover all details or variations in equipment or cover every possible situation regarding
installation, operation, or maintenance. Should problems arise that are not covered sufficiently in the text, immediately
contact Customer Support for further information.
Protecting Operating Processes
A failure of this device – for whatever reason -- may leave an operating process without appropriate protection and could result
in possible damage to property or injury to persons. To protect against this, you should review the need for additional backup
equipment or provide alternate means of protection (such as alarm devices, output limiting, fail-safe valves, relief valves,
emergency shutoffs, emergency switches, etc.). Contact Remote Automation Solutions for additional information.
Returning Equipment
If you need to return any equipment to Remote Automation Solutions, it is your responsibility to ensure that the equipment
has been cleaned to safe levels, as defined and/or determined by applicable federal, state and/or local law regulations or
codes. You also agree to indemnify Remote Automation Solutions and hold Remote Automation Solutions harmless from any
liability or damage which Remote Automation Solutions may incur or suffer due to your failure to ensure device cleanliness.
Grounding Equipment
Ground metal enclosures and exposed metal parts of electrical instruments in accordance with OSHA rules and regulations as
specified in Design Safety Standards for Electrical Systems, 29 CFR, Part 1910, Subpart S, dated: April 16, 1981 (OSHA rulings are
in agreement with the National Electrical Code). You must also ground mechanical or pneumatic instruments that include
electrically operated devices such as lights, switches, relays, alarms, or chart drives.
Important: Complying with the codes and regulations of authorities having jurisdiction is essential to ensuring personnel
safety. The guidelines and recommendations in this manual are intended to meet or exceed applicable codes and regulations.
If differences occur between this manual and the codes and regulations of authorities having jurisdiction, those codes and
regulations must take precedence.
Protecting from Electrostatic Discharge (ESD)
This device contains sensitive electronic components which be damaged by exposure to an ESD voltage. Depending on the
magnitude and duration of the ESD, it can result in erratic operation or complete failure of the equipment. Ensure that you
correctly care for and handle ESD-sensitive components.
System Training
A well-trained workforce is critical to the success of your operation. Knowing how to correctly install, configure, program,
calibrate, and trouble-shoot your Emerson equipment provides your engineers and technicians with the skills and confidence
to optimize your investment. Remote Automation Solutions offers a variety of ways for your personnel to acquire essential
system expertise. Our full-time professional instructors can conduct classroom training at several of our corporate offices, at
your site, or even at your regional Emerson office. You can also receive the same quality training via our live, interactive
Emerson Virtual Classroom and save on travel costs. For our complete schedule and further information, contact the Remote
Automation Solutions Training Department at 800-338-8158 or email us at education@emerson.com.
Ethernet Connectivity
This automation device is intended to be used in an Ethernet network which does not have public access. The inclusion of this
device in a publicly accessible Ethernet-based network is not recommended.
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Replacing the CPU Enclosure & Electronics
You can replace the CPU enclosure and its individual boards in the field provided that the
replacement has the exact same part number and version.
There is considerable overlap between the different field replacement procedures for the items
covered in this guide. This guide presents several discrete tasks which are used, and then
references them in procedures as they are needed.
Restriction
Hazardous area approvals require that any part replaced in the field be the exact same part (“like-
for-like”). Upgrading or substituting different parts violates hazardous area certification.
Contents
Removing/Restoring Main Power .............................................................................. 3
Removing Main Power ...................................................................................... 4
Restoring Main Power ....................................................................................... 5
Replacing the HMI Module ........................................................................................ 5
Removing the HMI Module ............................................................................... 6
Replacing the HMI Module ................................................................................ 6
Disconnecting the Cable Between the CPU Enclosure and the Sensor ........................ 7
Detaching/Re-Attaching the CPU Enclosure from/to the Battery Compartment ........ 7
Detaching the CPU Enclosure from the Battery Compartment .......................... 7
Re-attaching the CPU Enclosure to the Battery Compartment ........................... 9
Removing/Replacing the CPU Enclosure Cover (Top) ................................................ 9
Removing the CPU Enclosure Cover (Top) ....................................................... 10
Replacing the CPU Enclosure Cover (Top) ....................................................... 11
Removing/Replacing the Adapter Board ................................................................. 12
Removing the Adapter Board .......................................................................... 12
Replacing the Adapter Board .......................................................................... 14
Removing/Replacing the CPU Board ....................................................................... 14
Removing the CPU Board ................................................................................ 14
Replacing the CPU Board ................................................................................ 16
Removing/Replacing the Optional 6-Channel Expansion I/O Board ......................... 17
Removing the Optional 6-Channel Expansion I/O Board .................................. 18
Replacing the 6-Channel Expansion I/O Board ................................................. 18
Removing/Replacing the Connectivity Board .......................................................... 18
Removing the Connectivity Board................................................................... 20
Replacing the Connectivity Board ................................................................... 21
Removing/Replacing the CPU Enclosure (Bottom) .................................................. 21
Removing the CPU Enclosure (Bottom) ........................................................... 22
Replacing the CPU Enclosure (Bottom) ........................................................... 23
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Refer to the table below for the correct field replacement part numbers.
Item
Field Replacement Kit
Part Number
CPU Board 621678-01-0
Optional 6-Channel Expansion I/O Board 400215010-KIT
Connectivity Board 400211010-KIT
Adapter Board 400209010-KIT
CPU Enclosure - Bottom – (black plastic) 399260-01-0
CPU Enclosure – Top- (black plastic) 399264-01-0
CPU Enclosure Assembly with Base I/O - Ethernet disabled 621673-01-0
CPU Enclosure Assembly with Base I/O - Ethernet enabled 621674-01-0
CPU Enclosure Assembly with optional 6-Channel Expansion
I/O board – Ethernet disabled
621675-01-0
CPU Enclosure Assembly with optional 6-Channel Expansion
I/O board - Ethernet enabled
621676-01-0
UL File Number for these kits: E192567
Required Tools
#1 Phillips-head screwdriver
#2 Phillips-head screwdriver
Hexagonal torque wrenches. Ranges must include 1 to 2 in-lbs (0.1 to 0.2 N-m), 4 to 6 in-lbs
(0.5 to 0.7 N-m), 5 to 7 in-lbs (0.6 to 0.8 N-m), and 7 to 9 in-lbs (0.8 to 1.0 N-m).
Electrical Ratings:
Input Voltage: 10.5 Vdc to 30 Vdc external supply (Max power at 10 watts)
Ambient Temperature Range:
May be used up to a maximum ambient temperature of 80°C and a minimum ambient
temperature of –40°C; refer to the data plate attached to the device for ambient temperature.
WARNING
EXPLOSION HAZARD – Substitution of any components may impair suitability for Class 1,
Division 2.
WARNING
EXPLOSION HAZARD – Do not disconnect equipment unless power has been removed or the
area is known to be non-hazardous.
DANGER
EXPLOSION HAZARD: Ensure the area in which you perform this operation is non-hazardous.
Performing this operation in a hazardous area could result in an explosion.
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Tip
Because some of these procedures involve removing small parts such as screws and standoffs, we
recommend you provide a container for holding small parts.
Components of CPU Enclosure
1
CPU enclosure (bottom)
2
CPU board
3
SRAM backup battery
4
Adapter board
5
Connectivity board
6
Connection for optional 6-Channel Expansion I/O Board (underneath
CPU) – (FB2200 only)
7
Ethernet port (active on FB2200 only)
8
Screws (6) if you have the 6-channel expansion I/O board installed
underneath, (4) if you do not.
Removing/Restoring Main Power
Except when replacing batteries or the HMI module, you must always remove main power when
performing field replacements.
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Removing Main Power
Before you begin any of these procedures, you must remove main power. Terminal block TB2 (pins
1,3,5,7) includes connections for DC power (DCIN+, DCIN-) and battery/ solar power (BATT+,
BATT–). The internal battery (used with solar power) also has its own internal connectors inside the
battery compartment.
1.
Open the door of the flow computer enclosure.
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2.
Unplug TB2 (pins 1,3,5,7) to deactivate DC or battery/solar power. This shuts OFF power
from either an external power supply or the internal battery pack/solar panel.
Restoring Main Power
When you are done with all field replacement activities, you can restore main power. Plug in
terminal block TB2 (pins 1,3,5,7) to restore power.
Once you restore main power, close the flow computer enclosure door.
Removing/Replacing the HMI Module
The HMI module attaches to the outside of the CPU enclosure cover.
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Removing the HMI Module
1.
Use a #1 Phillips-head screwdriver to loosen the four captive fastening screws that attach the
HMI module to the CPU enclosure cover.
Captive Screws
2.
Grasp the HMI module and remove it by gently pulling it straight out.
Replacing the HMI Module
1.
To replace the HMI module, line up the printed circuit board (PCB) with the slot on the back
and gently press it back on.
2.
Tighten the four captive fastening screws with a torque value of 4 to 6 in.-lbs. (0.5 to 0.7 N-
m).
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Disconnecting the Cable Between the CPU Enclosure and the Sensor
Disconnect the cable between the CPU enclosure and the sensor module. To do this, press down on
the outer edge of the connection tab, then pull the connectors apart.
Detaching/Re-Attaching the CPU Enclosure from/to the Battery Compartment
UL Listed CPU Box Field Installed Accessory Kit for Use in Class I, Division 2, Groups A, B, C, and D
Flow Computer CPU Box Option 1 Field Installed Accessory Kit Part No. 621673-01-0 for use
with UL Listed Model Series FB2100 and FB2200.
Flow Computer CPU Box Option 2 Field Installed Accessory Kit Part No. 621674-01-0 for use
with UL Listed Model Series FB2100 and FB2200.
Flow Computer CPU Box Option 3 Field Installed Accessory Kit Part No. 621675-01-0 for use
with UL Listed Model Series FB2100 and FB2200.
Flow Computer CPU Box Option 4 Field Installed Accessory Kit Part No. 621676-01-0 for use
with UL Listed Model Series FB2100 and FB2200.
This procedure applies if you are replacing an entire CPU enclosure with its electronics. In addition,
most field replacements of components inside the CPU enclosure require you to remove the CPU
enclosure from the flow computer enclosure.
Detaching the CPU Enclosure from the Battery Compartment
1.
Remove the HMI module. See Removing the HMI Module on page 6 for details.
2.
Disconnect the cable between the CPU enclosure and the sensor. See Disconnecting the Cable
Between the CPU Enclosure and the Sensor on page 7.
3.
Use a #2 Phillips-head screwdriver to loosen the four captive fastening screws that hold the
CPU enclosure to the battery compartment.
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4.
Gently pull the CPU enclosure out of the flow computer enclosure.
Re-attaching the CPU Enclosure to the Battery Compartment
1.
Line up the CPU enclosure's captive fastening screws with their matching holes on the other
assemblies and battery compartment. Press the enclosure screws onto the holes and hold
the CPU enclosure while tightening each of the captive fastening screws with a torque of 7 to
9 in-lbs (0.8 to 1.0 N-m).
2.
Connect the cable between the CPU and the sensor module and make sure it has clearance.
3.
Replace the HMI module. See Replacing the HMI Module on page 6.
Removing/Replacing the CPU Enclosure Cover (Top)
UL Listed CPU Enclosure Cover (Top) Field Installed Accessory Kit for Use in Class I, Division 2,
Groups A, B, C, and D
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Flow Computer CPU Enclosure Cover (Top) Field Installed Accessory Kit Part No. 399264-01-
0 for use with UL Listed Model Series FB2100 and FB2200.
You remove the CPU enclosure cover to gain access to the inside of the CPU enclosure, to perform
a field replacement, or if you need to replace the CPU enclosure cover itself. Replace the CPU
enclosure cover when you are done with your field replacement procedure.
Removing the CPU Enclosure Cover (Top)
1. Remove the HMI module. See Removing the HMI Module on page 6.
2. Disconnect the cable between the CPU enclosure and the sensor. See Disconnecting the Cable
Between the CPU Enclosure and the Sensor on page 7.
3. Detach the CPU enclosure from the battery compartment. See Detaching the CPU Enclosure
from the Battery Compartment page 7.
4. Use a #2 Phillips-head screwdriver to loosen the two screws that hold the CPU enclosure
cover (top) to the CPU enclosure (bottom). Save the screws.
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5. Pull off the CPU enclosure cover to reveal the inside of the CPU enclosure.
Replacing the CPU Enclosure Cover (Top)
1.
Press the CPU enclosure cover (whether the original cover or a new replacement cover)
against the CPU enclosure.
2.
Tighten the two screws to attach the cover. Use a torque value of 5 to 7 in-lbs (0.6 to 0.8 N-
m.
3.
Re-attach the CPU enclosure to the battery compartment. See Re-attaching the CPU Enclosure
to the Battery Compartment on page 9.
4.
Re-connect the cable between the CPU enclosure and the sensor.
5.
Replace the HMI module. See Replacing the HMI Module on page 6.
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Removing/Replacing the Adapter Board
UL Listed Adapter Board Field Installed Accessory Kit for Use in Class I, Division 2, Groups A, B, C,
and D
Flow Computer Adapter Board Field Installed Accessory Kit Part No. 400209010-KIT for use
with UL Listed Model Series FB2100 and FB2200.
The adapter board resides inside the CPU enclosure. It provides a connection through a slot in the
CPU enclosure cover to the HMI module. You would remove/replace the adapter board if the
adapter board itself fails, or as a step in the field replacement of the CPU board, the 6-channel
expansion I/O board, the connectivity board, or the CPU enclosure (bottom).
1
Adapter Board
2
CPU board
3
SRAM backup battery
4
CPU board connector to the adapter board
5
CPU screws nearest to the adapter board
Removing the Adapter Board
1.
Remove the HMI module. See Removing the HMI Module on page 6.
2.
Disconnect the cable between the CPU enclosure and the sensor. See Disconnecting the Cable
Between the CPU Enclosure and the Sensor on page 7.
3.
Detach the CPU enclosure from the battery compartment. See Detaching the CPU Enclosure
from the Battery Compartment on page 7.
4.
Remove the CPU enclosure cover. See Removing the CPU Enclosure Cover (Top) on page 10.
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5.
Remove the two CPU board screws closest to the adapter board. This allows some free
movement of the CPU board when you remove the adapter board.
6.
With both hands, place your thumbs and fingers on each side of the adapter board. Four
plastic tabs on the bottom of the CPU enclosure hold it in place. Gently pull it up just enough
so it is clear of the plastic tabs.
7.
Once clear of the plastic tabs, slide it off the CPU board connector and set it aside.
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Replacing the Adapter Board
1.
Gently slide the adapter board onto the CPU board connector.
2.
Once on the connector, carefully lift it just enough so it moves to sit inside the four plastic
tabs on the bottom of the CPU enclosure.
3.
Replace the two CPU board screws nearest to the adapter board. Torque the screws to 1 to 2
in-lbs (0.1 to 0.2 N-m).
4.
Replace the CPU enclosure cover. See Replacing the CPU Enclosure Cover (Top) on page 11.
5.
Attach the entire CPU enclosure assembly to the battery compartment inside the flow
computer enclosure. See Re-attaching the CPU Enclosure to the Battery Compartment on page
9.
6.
Re-connect the cable between the CPU enclosure and the sensor.
7.
Replace the HMI module. See Replacing the HMI Module on page 6.
Removing/Replacing the CPU Board
UL Listed CPU Board Field Installed Accessory Kit for Use in Class I, Division 2, Groups A, B, C, and D
Flow Computer CPU Board Field Installed Accessory Kit Part No.621678-01-0 for use with UL
Listed Model Series FB2100 and FB2200.
The CPU board resides inside the CPU enclosure. You would remove/replace the CPU board if it
fails, or as a step in the field replacement of the 6-channel expansion I/O board, the connectivity
board, or the CPU enclosure (bottom).
Removing the CPU Board
1.
Remove the HMI module. See Removing the HMI Module on page 6.
2.
Disconnect the cable between the CPU enclosure and the sensor. See Disconnecting the Cable
Between the CPU Enclosure and the Sensor on page 7.
3.
Detach the CPU enclosure from the battery compartment. See Detaching the CPU Enclosure
from the Battery Compartment on page 7.
4.
Remove the CPU enclosure cover. See Removing the CPU Enclosure Cover (Top) on page 10.
5.
Remove the adapter board. See Removing the Adapter Board on page 12.
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6.
Use a #1 Phillips-head screwdriver to remove the screws that hold down the CPU board. Save
the screws. If you have the 6-channel expansion I/O board installed, there are 6 screws; if the
board is not present, there are 4 screws.
1
2
3
I/O board installed underneath) or four screws (without the board).
: The two left-most screws in this picture have been removed to ease
removal of the adapter board.
4
7.
Use a small flat head screwdriver to push the intermediate cable connector off its mating
connector on the CPU board.
8.
Gently slide the CPU board out of its connector on the connectivity board.
9.
If the CPU board itself is to be replaced with a new CPU board, take the SRAM backup battery
out as you will need it for the new replacement CPU board. Otherwise, leave the battery in
the board.
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Replacing the CPU Board
1.
Gently slide the CPU board into its connector on the connectivity board. Make sure it is firmly
in place.
2.
Attach the CPU board using the screws saved from when you removed it but leave the two
screws nearest the adapter board off.
3.
Gently slide the adapter board onto its mating connector on the CPU board and move it so it
fits between the four plastic tabs on the bottom of the CPU enclosure. Now finish attaching
the CPU board using the two screws nearest the adapter board Torque all CPU board screws
to 1 to 2 in-lbs (0.1 to 0.2 N-m).
4.
Connect the intermediate cable to its mating connector on the CPU board. Ensure that the
other end of the cable goes out the round hole in the bottom of the CPU enclosure.
5.
If you removed the SRAM backup battery, slide it into its slot on the CPU board. Be sure to
align the positive side properly as marked on the battery housing.
6.
Replace the CPU enclosure cover. See Replacing the CPU Enclosure Cover (Top) on page 11.
7.
Reattach the CPU enclosure to the battery compartment. See Re-attaching the CPU Enclosure
to the Battery Compartment on page 9.
8.
Re-connect the cable between the CPU enclosure and the sensor.
9.
Reattach the HMI module. See Replacing the HMI Module on page 6.
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Removing/Replacing the Optional 6-Channel Expansion I/O Board
UL Listed Optional 6-Channel Expansion I/O Board Field Installed Accessory Kit for Use in Class I,
Division 2, Groups A, B, C, D
Flow Computer 6-Channel Expansion I/O Board Field Installed Accessory Kit Part No.
400215010-KIT for use with UL Listed Model Series FB2100 and FB2200.
The optional 6-channel expansion I/O board resides inside the CPU enclosure. You would
remove/replace the optional 6-channel expansion I/O board if it fails, or as a step in the field
replacement of the connectivity board, or the CPU enclosure (bottom).
1
6-channel expansion I/O board
2
Standoffs that connect directly with connections on the bottom of the
CPU enclosure. There are a pair of holds for each standoff. For the board
positioned as shown, use the right-most hole. The other holes are used
when this board resides in an FB1200
3
Standoffs that are held onto the 6-Channel Expansion I/O Board by screws
underneath the board. There are a pair of holes for each standoff. For the
board positioned as shown, use the right-most hole. The other holes are
used when this board resides in an FB1200.
4
Socket on the connectivity board for the 6-channel Expansion I/O Board.
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Removing the Optional 6-Channel Expansion I/O Board
1.
Remove the HMI module. See Removing the HMI Module on page 6.
2.
Disconnect the cable between the CPU enclosure and the sensor. See Disconnecting the Cable
Between the CPU Enclosure and the Sensor on page 7.
3.
Detach the CPU enclosure from the battery compartment. See Detaching the CPU Enclosure from
the Battery Compartment on page 7.
4.
Remove the CPU enclosure cover. See Removing the CPU Enclosure Cover (Top) on page 10.
5.
Remove the adapter board. See Removing the Adapter Board on page 12.
6.
Remove the CPU board. See Removing the CPU Board on page 14.
7.
Remove the two standoffs closest to the connectivity board; these screw directly through the
board to connections on the CPU enclosure bottom.
The other two standoffs have separate screws underneath that hold them onto the expansion
I/O board. (If you are replacing the board itself because it failed, remove these standoffs and
screws as well so you can re-use them on the replacement board.)
8.
Carefully slide the 6-channel expansion I/O board out of its socket on the connectivity board and
set it aside.
Replacing the 6-Channel Expansion I/O Board
1.
If you removed standoffs that are held on the expansion I/O board, attach them to the new
replacement expansion I/O board. Torque standoffs to 1 to 2 in-lbs (0.1 to 0.2 N-m).
2.
Carefully slide the 6-channel expansion I/O board into its slot in the connectivity board and
make sure it is firmly in place.
3.
Secure the board to the bottom of the CPU enclosure by tightening the two standoffs that have
connections on the CPU enclosure. Torque standoffs 1 to 2 in-lbs (0.1 to 0.2 N-m).
4.
Attach the CPU board. See Replacing the CPU Board on page 16.
5.
Reattach the adapter board. See Replacing the Adapter Board on page 14.
6.
Reattach the CPU enclosure cover. See Replacing the CPU Enclosure Cover (Top) on page 11.
7.
Re-attach the CPU enclosure to the battery compartment. See Re-attaching the CPU Enclosure to
the Battery Compartment on page 9.
8.
Re-connect the cable between the CPU enclosure and the sensor module.
9.
Reattach the HMI module. See Replacing the HMI Module on page 6.
Removing/Replacing the Connectivity Board
UL Listed Connectivity Board Field Installed Accessory Kit for Use in Class I, Division 2, Groups A, B, C,
and D
Flow Computer Connectivity Board Field Installed Accessory Kit Part No. 400211010-KIT for
use with UL Listed Model Series FB2100 and FB2200.
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Remote Automation Solutions FB2100/FB2200 Flow Computer CPU Enclosure and Electronics Field User guide

Brand
Remote Automation Solutions
Model
FB2100/FB2200 Flow Computer CPU Enclosure and Electronics Field
Type
User guide
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